Dual density systems and methods for bedding applications

ABSTRACT

Embodiments include a dual density mattress including a base, the base having a first density, a plurality of cavities, where the plurality of cavities are defined by the base, a plurality of foam pillars, the foam pillars having a second density different from the first density, where the plurality of foam pillars are operably configured to be positioned within the plurality of cavities.

RELATED APPLICATION

The present application is a non-provisional application claimingpriority to U.S. Provisional Application No. 62/542,106, filed on Aug.7, 2017, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

Embodiments of the technology relate, in general, to bedding, mattress,and toppers, and in particular to bedding, mattresses, and toppersincorporating dual density systems and methods.

BACKGROUND

A mattress is a large pad for supporting the reclining body, used as abed or as part of a bed. Mattresses may consist of a quilted orsimilarly fastened case, usually of heavy cloth, that contains hair,straw, cotton, foam rubber, etc., or a framework of metal springs.Mattresses may also be filled with air or water.

Mattresses are usually placed on top of a bed base which may be solid,as in the case of a platform bed, or elastic, e.g. with an upholsteredwood and wire box spring or a slatted foundation. Mattresses may besupplied with a secondary mattress and/or a removable “topper.” Amattress may include an innerspring core and cotton batting orfiberfill. Modern mattresses usually contain either an inner spring coreor materials such as latex, viscoelastic or other flexible polyurethanefoams. Other fill components include insulator pads over the coils thatprevent the bed's upholstery layers from cupping down into theinnerspring, as well as polyester fiberfill in the bed's top upholsterylayers. In 1899 James Marshall introduced the first individually wrappedpocketed spring coil mattress now commonly known as Marshall coils.Mattresses may also be filled with air or water, or a variety of naturalfibers, such as in futons.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be more readily understood from a detaileddescription of some example embodiments taken in conjunction with thefollowing figures:

FIG. 1 is a partial front perspective view of a dual density mattressaccording to one embodiment.

FIG. 2 is a partial exploded view of the dual density mattress of FIG.1, shown with a plurality of foam pillars removed from a plurality ofmattress cavities.

FIG. 3 is a more detailed partial front perspective view of the dualdensity mattress shown in FIG. 1.

FIG. 4 is a partial front perspective view of the dual density mattressof FIG. 3, shown with the plurality of foam pillars removed.

FIG. 5 is a right side cross-sectional view of a dual density mattressshown defining a cavity that is configured to retain a foam pillaraccording to one embodiment.

FIG. 6 is a top view of a dual density mattress shown with a pluralityof foam pillars that are rotatable within a plurality of cavitiesaccording to one embodiment.

FIG. 7 is a partial front perspective view of a dual density mattressaccording to an alternate embodiment.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, and use of the apparatuses, systems, methods, andprocesses disclosed herein. One or more examples of these non-limitingembodiments are illustrated in the accompanying drawings. Those ofordinary skill in the art will understand that systems and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting embodiments. The features illustrated ordescribed in connection with one non-limiting embodiment may be combinedwith the features of other non-limiting embodiments. Such modificationsand variations are intended to be included within the scope of thepresent disclosure.

Reference throughout the specification to “various embodiments,” “someembodiments,” “one embodiment,” “some example embodiments,” “one exampleembodiment,” or “an embodiment” means that a particular feature,structure, or characteristic described in connection with any embodimentis included in at least one embodiment. Thus, appearances of the phrases“in various embodiments,” “in some embodiments,” “in one embodiment,”“some example embodiments,” “one example embodiment,” or “in anembodiment” in places throughout the specification are not necessarilyall referring to the same embodiment. Furthermore, the particularfeatures, structures or characteristics may be combined in any suitablemanner in one or more embodiments.

Described herein are example embodiments of apparatuses, systems, andmethods for bedding, mattress, padding, cushion, seating, reclining, andfurniture applications. In one example embodiment, one or a plurality ofcavities or apertures can retain a plurality of foam components to forma padding system or assembly. In some embodiments, each cavity canpartially, substantially, or wholly retain a foam or padding component.In some embodiments, each cavity can contain a plurality of foamcomponents having the same or different shapes, sizes, and materials. Insome embodiment, each pocket can contain a combination of foamcomponents, springs, innersprings, coils, padding, support material,cushion material, absorbent material, elastic material, memory retentionmaterial, combinations thereof, or the like.

The examples discussed herein are examples only and are provided toassist in the explanation of the apparatuses, devices, systems andmethods described herein. None of the features or components shown inthe drawings or discussed below should be taken as mandatory for anyspecific implementation of any of these the apparatuses, devices,systems or methods unless specifically designated as mandatory. For easeof reading and clarity, certain components, modules, or methods may bedescribed solely in connection with a specific figure. Any failure tospecifically describe a combination or sub-combination of componentsshould not be understood as an indication that any combination orsub-combination is not possible. Also, for any methods described,regardless of whether the method is described in conjunction with a flowdiagram, it should be understood that unless otherwise specified orrequired by context, any explicit or implicit ordering of stepsperformed in the execution of a method does not imply that those stepsmust be performed in the order presented but instead may be performed ina different order or in parallel.

Referring now to FIGS. 1-6, one embodiment of a dual density mattress 10is shown having a base 12 that can incorporate a plurality of foampillars 14. The base 12 can include a substantially contiguous bottomlayer 25 (see FIG. 5) that can cooperate with an upper layer 13 (FIG. 5)to define a plurality of apertures 15. In the illustrated example theapertures 15 can have a substantially cylindrical shape. The apertures15 can be sized to accept a plurality of foam pillars 14 such that thefoam pillars are seated within the apertures 15. Referring to FIG. 5,the foam pillars 14 can be positioned within the apertures 15 such thatthe apertures 15 are substantially filled by the foam pillars 14. Forexample, when the foam pillars 14 are positioned within the apertures 15a top surface 17 of the upper layer 13 may be substantially contiguousand/or planar with a top surface 18 of the foam pillar 14. The upperlayer 13 and bottom layer 25 can be fused or welded, for example, suchthat the upper layer 13 and bottom layer 25 are shipped as a singlecomponent. Alternatively, the upper layer 13 and bottom layer 25 can bemonolithically formed as a unitary, one piece construction. The base 12can have a first density, where the foam pillars 14 can have a seconddensity, such that a dual density system can be achieved.

In embodiments incorporating a foam pillar 14 it will be appreciatedthat the foam pillar can have the shape of a cylinder, hour glass,barrel, square, triangle, square, pentagon, hexagon, heptagon, octagon,nonagon, decagon, cube, cuboid, sphere, cone, hexagonal prism, pyramidbase, dissimilar geometries, polygons, or the like. It will beappreciated that any suitable aperture 15 is contemplated having anysuitable configuration or position.

Dual density mattresses 10 in accordance with versions described hereincan be made with memory or viscoelastic foam, latex, or urethanes whichcan create a comfortable bedding surface. The dual density mattresses 10can incorporate dual density features, such as those described herein,having any suitable configuration.

Example configurations of the dual density mattress 10 can have aperture15 height of from about 0.25 inches to about 4 inches, from about 1 inchto about three inches, from about 2 inches to about 5 inches, from about5 inches to about 12 inches, or any suitable combination thereof. Itwill be appreciated that the apertures 15 associated with the dualdensity mattress 10 can vary in size and shape to create, for example,ergonomic configurations.

The dual density mattress 10 can include foam pillars 14 constructedfrom any suitable material such as polyurethane foam, polyethylene foam,polyether foam, viscoelastic memory foam, polyester fibers, gel foam,latex foam, other chemistry based technologies, or combinations thereof.Individual pockets can include any suitable foam components having anysuitable shape such as cylinder, hour glass, barrel, square, triangle,square, pentagon, hexagon, heptagon, octagon, nonagon, decagon, cube,cuboid, sphere, cone, hexagonal prism, pyramid base, dissimilargeometries, or combinations thereof. It is also contemplated that thecavities can be adjustable, such as with air pressure or temperature, tochange the sleep conditions. It is also contemplated that the mattresscan normalize or adjust to a pre-programmed user condition, such as adesired temperature, automatically. The foam pillars can be configuredfrom a uniform material, can include different layers of material, canhave uniform characteristics, or can have variable characteristics. Forexample, a foam pillar (not shown) may have a top portion that is formedfrom a soft breathable material, where a bottom portion of the same foampillar may be formed from a more rigid foam.

The dual density mattress 10 can encase the plurality of foam pillars14, such as with a sheet or layer of material, or the top surface 18 ofthe foam pillars 14 can be exposed. The apertures 15 can be sized topartially accept the foam pillars 14, to accept the foam pillars 14 in afriction fit, to accept the foam pillars such that an air gap (notshown) is present between the pillars and the cavity, or any othersuitable arrangement. The foam pillars 14 can be positioned whollywithin the apertures 15 of the dual density mattress 10 and can beretained with an adhesive, seal, weld, or can be seated without anattachment feature.

It will be appreciated that any suitable layer or section of materialcan retain any suitable component in any suitable fashion to form atopper, mattress, bedding, pad, or the like. In one version, each cavityof the dual density mattress can have a slot into which a component,such as a foam padding component, is inserted to complete the mattress,where different types of components can be used with the same base 12 toprovide a desirable configuration.

Referring to FIG. 1, the dual density mattress 10 can be divided into afirst section 20 and a second section 22, where the first section 20 canbe associated with a first sleeping individual and the second section 22can be associated with a second sleeping individual. Each of theindividuals may have different preferences for bedding comfort,hardness, elasticity, etc. In an example embodiment, the firstindividual may choose a first type of foam pillar 14 for insertion intothe apertures 15 of the first section 20. The second individuals mayselect a different type of foam pillar 14 for insertion into theapertures 15 of the second section 22, where each section 20, 22 iscustomizable. In an example embodiment, a base 12 may be standard oruniversal, where customization of the dual density mattress 10 can beachieved by interchanging desirable foam pillars 14 having any suitablecharacteristics. In one embodiment, the foam pillars or other componentscan be removable or replaceable from the dual density mattress 10 suchthat changes can be made over time based upon user preference.

It will be appreciated that within a particular section, such assections 20, 22, a user may vary the type and placement of foam pillars14, or the like. For example, a user may desire more support near theirlegs and a softer feel near their head. It is contemplated that the foampillars 14 can be rated so as to be selectable by a user for differentregions. The foam pillars can be colored, marked, or otherwise indicatethe characteristics for proper placement by a user.

Example embodiments described herein can include any suitable feature,component, device, or mechanism wholly or partially retained within acavity, pocket, pod, enclosure, capsule, or the like. In one embodiment,a user can select from a variety of core, layer, and/or pillar optionsto obtain the desired characteristics of softness, comfort, rigidity,heat retention, durability, stiffness, elasticity, memory retention, orthe like.

It is contemplated that the dual density mattress 10 may be shippedusing a novel method. The plurality of apertures 15 in the dual densitymattress may allow for the dual density mattress 10 to be compressed orotherwise packaged to take up very little space. In particular, thespacing of the apertures 15 may allow for the dual density mattress 10to be easily rolled into a compact shape. The foam pillars 14, or otherinsertable element, can be shipped separately and inserted by the userafter unrolling the base 12, for example. The foam pillars 14 can alsobe compacted for ease of packaging and/or shipment.

Referring to FIG. 7, an alternate embodiment of a dual density mattress110 is shown. As illustrated, it will be appreciated that any suitablearrangement of cavities or apertures 115 is contemplated to accommodateany suitable number and arrangement of foam components 114. Asillustrated, a base 120 defining the apertures 120 can have an offsetheight of, for example, from about 0.25 inches to about 0.5 inchesrelative to the inside foam component 114. The offset height, or gapbetween the top of the foam component and the top of the base 120, canbe from about 0.10 inches to about 1 inch, from about 0.25 inches toabout 1 inch, or any other suitable distance. The base 120 or supportlayer can have an uncompressed height of, for example, from about 0.5inches to about 8 inches. Each foam component 114 or support pillar canhave an uncompressed height of, for example, from about 0.5 inches toabout 8 inches. In one embodiment, a first diameter of the aperture 115or cavity can be greater than a second diameter of the inside pillarfoam or foam component 114. The first diameter can be from about ⅛ inchto about 1/16 inch less than the second diameter. The base 120 can havean aperture 115 depth of, for example, from about 3 inches to about 8inches. The inside pillar or foam component 114 can have a height offrom about 2.75 inches to about 3 inches.

It will be appreciated that any suitable features and characteristicsare contemplated. For example, the foam pillars (e.g., 14) can have acompressed deflection strength of from about 0.5 psi to about 4.6 psi inaccordance with ASTM D1056. The foam pillar density can be from about 1pcf to about 11 pcf in accordance with ASTM D1056. The compression setcan be from about 2% to about 3(%) in accordance with ASTM D1056. Anysuitable number of zones or sections (e.g., sections 20, 22) arecontemplated having any number of associated foam pillars, having anysuitable shape, etc. Foam pillars or foam components can be formed byany suitable process. Pillars can be converted by water jet or a diecutter system. Pillars can be poured in cavity using a foam processingsystem.

In various embodiments disclosed herein, a single component can bereplaced by multiple components and multiple components can be replacedby a single component to perform a given function or functions. Exceptwhere such substitution would not be operative, such substitution iswithin the intended scope of the embodiments.

Some of the figures can include a flow diagram. Although such figurescan include a particular logic flow, it can be appreciated that thelogic flow merely provides an exemplary implementation of the generalfunctionality. Further, the logic flow does not necessarily have to beexecuted in the order presented unless otherwise indicated. In addition,the logic flow can be implemented by a hardware element, a softwareelement executed by a computer, a firmware element embedded in hardware,or any combination thereof.

The foregoing description of embodiments and examples has been presentedfor purposes of illustration and description. It is not intended to beexhaustive or limiting to the forms described. It will be appreciatedthat systems and embodiments described herein can be applied tomattresses, mattress cores, toppers, supportive layers, and any layerassociated with bedding, bedding materials, padding, padding materials,or the like. Numerous modifications are possible in light of the aboveteachings. Some of those modifications have been discussed, and otherswill be understood by those skilled in the art. The embodiments werechosen and described in order to best illustrate principles of variousembodiments as are suited to particular uses contemplated. The scope is,of course, not limited to the examples set forth herein, but can beemployed in any number of applications and equivalent devices by thoseof ordinary skill in the art. Rather it is hereby intended the scope ofthe invention to be defined by the claims appended hereto.

We claim:
 1. A dual density mattress comprising: (a) a base, the basehaving a first density; (b) a plurality of cavities, wherein theplurality of cavities are defined by the base; (c) a plurality of foampillars, the plurality of foam pillars having a second density differentfrom the first density, wherein the plurality of foam pillars areoperably configured to be positioned within the plurality of cavities.2. The dual density mattress of claim 1, wherein the plurality of foampillars are identical.
 3. The dual density mattress of claim 1, whereinthe plurality of foam pillars are constructed from different materials.4. The dual density mattress of claim 1, wherein the base has a firstsection with a first set of properties and a second section with asecond set of properties, wherein the first set of properties aredifferent from the second set of properties.
 5. The dual densitymattress of claim 4, wherein the first section includes foam pillarsconstructed from a first material and the second section includes foampillars constructed from a second material, wherein the first materialis different from the second material.
 6. The dual density mattress ofclaim 4, wherein the first section includes foam pillars having a firstdensity and the second section includes foam pillars having a seconddensity, wherein the first density is different from the second density.7. The dual density mattress of claim 6, wherein the first section andthe second section include foam pillars constructed from the same typeof material.
 8. The dual density mattress of claim 1, wherein the eachof the plurality of cavities has a substantially cylindricalconfiguration.
 9. The dual density mattress of claim 1, wherein each ofthe plurality of foam pillars has a substantially cylindricalconfiguration.
 10. The dual density mattress of claim 1, wherein each ofthe plurality of foam pillars is rotatable within each of the pluralityof cavities.
 11. The dual density mattress of claim 1, wherein a top ofeach of the plurality of foam pillars is planar with a top of an uppersection of the base.
 12. The dual density mattress of claim 1, whereinthe base has an upper section and a lower section.